Method for providing a pad to support heavy equipment

ABSTRACT

A method for supporting heavy equipment at a site is provided. The method includes constructing a plurality of pre-formed reinforced concrete blocks. Each of the concrete blocks is constructed by: providing a concrete form having internal dimensions of at least 1½ feet by 3 feet by 3 feet, inserting a plurality of reinforcing members within the form, pouring concrete into the form over the reinforcing members, allowing the concrete to cure to form a concrete block, and removing the concrete block from the form. The method further includes excavating the site to form an excavated area and placing the plurality of pre-formed reinforced concrete blocks on the excavated area. The present invention also provides a concrete pad which can be formed by the above-described method.

CROSS REFERENCE TO RELATED APPLICATION(S)

This application claims the benefit of U.S. Provisional PatentApplication No. 60/677,560, filed May 4, 2005, which is incorporated byreference as if fully set forth.

BACKGROUND

Poured concrete pads are typically used under loading, unloading,parking, and storage areas for trucks and other heavy equipment. Theloads associated with commercial and industrial equipment require thatthe poured concrete pads be substantial in size and sometimes reinforcedwith steel to carry loads of several thousand psi. Such concrete padscan have a thickness of approximately two feet +/− and are cast on-siteover reinforcing bars in order to provide the necessary strength tohandle heavy equipment traffic.

Known on-site concrete pad installation can be problematic because thethicker the pad, the longer the curing time. Many pads takeapproximately thirty days to cure. Further, since concrete may not cureproperly in cold temperatures or in the presence of excess moisture,installation schedules are often affected by weather conditions.

It would be desirable to provide a concrete pad for heavy commercial andindustrial vehicle traffic which may be easily and quickly installed inall temperatures, and which is not subject to an extended curing time.

SUMMARY

The present invention provides a method for supporting heavy equipmentat a site. The method includes constructing a plurality of pre-formedreinforced concrete blocks. Each of the concrete blocks is constructedin accordance with the following method by: providing a concrete formhaving internal dimensions of at least 1½ feet by 3 feet by 3 feet,inserting a plurality of reinforcing members within the form, pouringconcrete into the form over the reinforcing members, allowing theconcrete to cure to form a concrete block, and removing the concreteblock from the form. Preferably, the blocks include an interlockingfeature to allow load transfer and distribution between the blocks. Themethod further includes excavating the site to form an excavated areaand placing the plurality of pre-formed reinforced concrete blocks onthe excavated area. The present invention also provides a concrete padwhich can be formed by the above-described method.

BRIEF DESCRIPTION OF THE DRAWING(S)

The foregoing Summary as well as the following detailed description willbe readily understood in conjunction with the appended drawings whichillustrate preferred embodiments of the invention. In the drawings:

FIG. 1 shows a perspective view of a heavy equipment support padaccording to a preferred embodiment of the present invention.

FIG. 2 shows a perspective view of a preformed reinforced concrete blockof the support pad of FIG. 1 with a cutaway window showing a reinforcingskeleton.

FIG. 3 shows a perspective view of the reinforcing skeleton of theconcrete block of FIG. 2.

FIG. 4 shows a perspective view of a form, including the reinforcingskeleton of FIG. 3, for forming the concrete block of FIG. 2.

FIG. 5 shows a perspective view of a heavy equipment support padaccording to an alternative preferred embodiment of the presentinvention.

FIG. 6 shows a perspective view of a preformed reinforced concrete blockof the support pad of FIG. 5.

FIG. 7 shows a flowchart depicting a method for providing a heavyequipment support pad.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

Certain terminology is used in the following description for convenienceonly and is not considered limiting. Words such as “front”, “back”,“top” and “bottom” designate directions in the drawings to whichreference is made. This terminology includes the words specificallynoted above, derivatives thereof and words of similar import.Additionally, the terms “a” and “one” are defined as including one ormore of the referenced item unless specifically noted.

The preferred embodiments of the present invention are described belowwith reference to the drawing figures where like numerals represent likeelements throughout.

Referring to FIGS. 1-4, a heavy equipment support pad 10 according to apreferred embodiment of the present invention is shown. The pad 10includes a plurality of adjacent preformed reinforced concrete blocks20. The blocks 20 are preferably laid over a layer of leveling material12 in an excavated area 14 surrounded by a footer 16.

Each reinforced block 20 is preferably at least 1½ feet by 3 feet by 3feet in size. The block 20 shown in FIGS. 1 and 2 is a generallyrectangular prism. Alternatively, a block can be provided having anon-rectangular shape so long as the block is at least 1½ feet thick andmaintains a substantially flat bottom surface for contact with anexcavated area. For example, the block can be a hexagonal prism ortriangular prism, or any other suitable shape that can be placed inadjoining contact with other blocks for 100% area coverage. The block 20can alternatively be dimensioned slightly smaller than 1½ feet by 3 feetby 3 feet, for example 1 foot by 3 feet by 3 feet, depending onapplication requirements.

Each block 20 preferably includes reinforcing members. The reinforcingmembers preferably include internal longitudinal and transverse steelreinforcing bars (re-bar) 24, 26 in the form of a reinforcing skeleton22. As shown, fourteen (14) longitudinal bars 24 are substantiallyperpendicular to two (2) transverse reinforcing bars 26. The reinforcingbars 24, 26 can alternatively be provided in any suitable quantity andarrangement depending on strength and size requirements. Further, inalternative preferred embodiments, the reinforcing members can includefibers, such as glass, steel, carbon or polymer fibers, or can includeplates, tubes, or any other suitable material.

During manufacture of the block 20, the reinforcing members arepreferably arranged in a form 28 into which the concrete is poured andcured. The reinforcing members, such as the reinforcing bars 24, 26, arepreferably prefabricated, for example by welding, in the form of astable frame, such as the reinforcing skeleton 22, prior to insertioninto the form 28. Alternatively, the reinforcing members can be locatedwithin the form with the assistance of supporting structure on or in theform 28. The form 28 is preferably made of wood, steel, plastic, or anysuitable material and can be fixed in size or adjustable. While the form28 is in the shape of a rectangular prism, one skilled in the art willrecognize that the interior shape of the form is dependent on a desiredshape of the block to be created by the form. The block 20 is removedfrom the form 28 after the concrete has cured.

The excavated area 14 is preferably 1½-2½ feet deep. The layer ofleveling material 12 preferably includes gravel and/or sand spread overthe base of the excavated area 14 to a thickness of 4-8 inches.Preferably a footer 16 is provided around the perimeter of the excavatedarea 14 to prevent shifting of the blocks 20. The footer 16 can beconstructed from materials such as poured concrete, stone, concreteblock or other suitable stabilizing materials. The footer 16 may beinstalled new prior to the installation of the blocks 20, oralternatively, the footer 16 can be salvaged from a pre-existing pad orother pre-existing structure surrounding the excavated area 14. Theblocks 20 are preferably placed over the leveling material flush withgrade, or alternatively, slightly above grade to permit some settling.

Referring to FIGS. 5 and 6, an alternative preferred embodiment of thepresent invention is shown. A heavy equipment support pad 110 isprovided which includes preformed reinforced concrete blocks 120 havinginterlocking portions. The blocks 120 include reinforcing members suchas the reinforcing bars 24, 26 described above. The interlockingportions are preferably in the form of key projections 130 and key slots132. During assembly of the heavy equipment support pad 110, adjacentconcrete blocks 120 are connected by connecting their respective keyprojections 130 and key slots 132. For example, key projections 130 of afirst concrete block 120 are slid over key slots 132 of a secondconcrete block 120, to join the first and second concrete blocks 120.Preferably, the key projections and slots allow some load transferringcapability to distribute loads to adjacent blocks. While the keyingfeature is shown as requiring vertical alignment for installation, itcan also be in the form of projections and recesses in the sides of theblocks for horizontal interlocking during placement of the blocks. Also,while a single key feature is shown per side, more than one can beutilized. Further, it is possible to have the reinforcing membersextending into the key projections 130, as shown in FIG. 6, for betterload distribution and transfer.

Now referring to FIG. 7, a flow chart depicting a method 200 forproviding a pad to support heavy equipment, such as the heavy equipmentsupport pads 10, 110, is shown. In the method 200, a concrete formhaving overall internal dimensions of least 1½ feet by 3 feet by 3 feet(step 202) is provided. In one preferred embodiment, the providing ofthe form includes providing a form having a structure suitable forforming a block with interlocking portions. A plurality of reinforcingmembers are inserted within the form (step 204). Concrete is poured intothe form over the reinforcing members (step 206) and allowed to cure(step 208) forming a reinforced concrete block, such as the blocks20,120. In a step 210, the block is removed from the form. Preferably,the concrete is allowed to cure for at least 30 days prior toinstallation. Steps 202-210 are repeated to form a plurality ofreinforced concrete blocks.

In a step 212, a site is excavated to provide an excavated area at least1½ feet deep to the appropriate desired pad size. Preferably, a layer ofleveling material 4-8 inches thick is placed over the excavated area(step 214). Also, a stable footer is preferably provided within theexcavated area around the perimeter of the excavated area. The pluralityof pre-formed reinforced concrete blocks are placed on the excavatedarea over the leveling material (step 216). Preferably, the blocks arelocated using a crane, a front end loader or other equipment suitablefor positioning large and heavy loads. Preferably, each of the blocks isplaced adjacent to and in contact with at least one other of the blocks,and settling of the blocks is induced using a vibration leveling device.In the case where the blocks include interlocking portions, the placingof the concrete blocks includes connecting the interlocking portions ofthe adjacent blocks.

The above-described heavy equipment support pads 10, 110 according topreferred embodiments of the present invention, provide many advantagesover conventional on-site poured concrete pads. Preformed reinforcedconcrete blocks, such as the blocks 20, 120 of FIGS. 2 and 6, arerapidly installable and readily usable in high traffic areas. Theseblocks can be installed, as by the method 200, during facility downtimesor overnight, preventing interruption of work at a factory or otherindustrial or commercial facility. This method can be used to installcomplete pads or to repair sections of an existing pad within one weekor less, and preferably in one or two days for pads up to 5000 squarefeet. Further, unlike poured pads, the installation of the blocks is notaffected by temperature or adverse weather conditions.

Immediately after installation, the support pads 10, 110 including thereinforced blocks 20, 120 according to the above-described preferredembodiments can support heavy equipment such as trucks having a vehicleweight in excess of 50,000 pounds. A reinforced concrete block sized 1½ft by 3 ft by 3 ft weighs approximately 2000 pounds, while a 2 ft by 4ft by 4 ft block weighs approximately 4800 pounds. The size and weightof the blocks prevents them from shifting under the weight of largevehicles.

While the preferred embodiments of the invention have been described indetail above, the invention is not limited to the specific embodimentsdescribed above, which should be considered as merely exemplary. Furthermodifications and extensions of the present invention may be developed,and all such modifications are deemed to be within the scope of thepresent invention as defined by the appended claims.

1. A method of providing a pad for supporting heavy equipment at a site,the method comprising: constructing a plurality of pre-formed reinforcedconcrete blocks using a method comprising: providing a concrete formhaving internal dimensions of at least 1½ feet by 3 feet by 3 feet;inserting a plurality of reinforcing members within the form; pouringconcrete into the form over the reinforcing members; allowing theconcrete to cure to form a concrete block; and removing the concreteblock from the form; excavating the site to form an excavated area; andplacing the plurality of pre-formed reinforced concrete blocks on theexcavated area.
 2. The method of claim 1, further comprising forming afooter around at least a portion of a perimeter of the excavated area.3. The method of claim 1, further comprising excavating the site inproximity to a preexisting footer.
 4. The method of claim 1, furthercomprising applying a layer of leveling material over the excavatedarea.
 5. The method of claim 1, further comprising providing theconcrete form with features for forming interlocking portions on each ofthe plurality of concrete blocks and connecting adjacent ones of theconcrete blocks using the interlocking portions.
 6. The method of claim1, wherein the constructing the plurality of pre-formed concrete blocksfurther comprises: providing the concrete form with features for forminginterlocking portions on each of the plurality of concrete blocks,wherein at least one of the interlocking portions on each of theplurality of concrete blocks includes at least one projection; andinserting the plurality of reinforcing members within the form such thatat least one of the reinforcing members extends into the at least oneprojection; wherein the method further comprises: connecting adjacentones of the concrete blocks using the interlocking portions.
 7. Themethod of claim 1, further comprising: providing each of the pluralityof concrete blocks with at least one key projection and at least one keyslot; and connecting the key projection of at least a first one of theplurality of concrete blocks with the key slot of at least a second oneof the plurality of concrete blocks adjacent to the at least the firstone of the plurality of concrete blocks.
 8. The method of claim 1,further comprising providing the concrete form with internal dimensionsof at least 2 feet by 3 feet by 3 feet.
 9. The method of claim 1,wherein the inserting the plurality of reinforcing members includesinserting a plurality of steel reinforcing bars.
 10. The method of claim1, further comprising positioning the plurality of concrete blocks onthe excavated area using a crane.
 11. The method of claim 1, furthercomprising vibrating the plurality of blocks on the excavated area toinduce settling.
 12. The method of claim 1, further comprising placingthe plurality of pre-formed concrete blocks on the excavated area suchthat top surfaces of the plurality of blocks are substantially flushwith grade.
 13. A concrete pad for supporting heavy equipment at a sitecomprising: an excavated area; a plurality of pre-formed reinforcedconcrete blocks having dimensions of at least 1½ feet by 3 feet by 3feet positioned within the excavated area.
 14. The concrete pad of claim13, further comprising a footer formed around at least a portion of aperimeter of the excavated area.
 15. The concrete pad of claim 13,further comprising a layer of leveling material between the excavatedarea and the plurality of concrete blocks.
 16. The concrete pad of claim13, wherein each of the plurality of concrete blocks comprisesinterlocking portions and adjacent ones of the plurality of concreteblocks are connected together using the interlocking portions.
 17. Theconcrete pad of claim 13, wherein each of the plurality of pre-formedreinforced concrete blocks have dimensions of at least 2 feet by 3 feetby 3 feet.
 18. The concrete pad of claim 13, wherein each of theplurality of pre-formed reinforced concrete blocks includes reinforcingbars.
 19. The concrete pad of claim 13, wherein each of the plurality ofpre-formed reinforced concrete blocks comprises reinforcing membersdisposed therein and interlocking portions including at least oneprojection, wherein at least one of the reinforcing members extends intothe at least one projection.
 20. The concrete pad of claim 13, wherein atop surface of each of the plurality of pre-formed reinforced concreteblocks is substantially flush with grade.